NEW THINKING.

NEW POSSIBILITIES

Training PLC Level#3

Instructors
Carlos Silva & Paul Davis
Technical Support Group – HMMA
2012-01
■ Agenda NEW THINKING. NEW POSSIBILITIES

Content
Before you Begin
About This Lab
Tool & Prerequisites
PLC Contrologix 5000 Version 13.04
Panel View Builder
Hands on Lab brief description
Hands on Lab#1 PLC3
Hands on Lab#2 PLC3
Hands on Lab#3 PLC3
Hands on Lab#4 PLC3
Hands on Lab 1: Mixer And Blender and Tank
Introduction the Lab – Mixer and Blender
PLC Tags to simulate Panel Builder Animation
PLC Software Create New Project
PLC Software Create Routine Mixer and Blender
Use JSR instruction – call PLC routine Mixer and Blender
How Implement PLC Instructions RSLogix 5000
Step#1 Logic to Open/Close Valve V1 – Make Up Valve
Mixer and Blender Download PLC Software
Use Panel View to Check PLC Software
Step#2 Implemented PLC Logic to temporize Agitator
Mixer and Blender Download PLC Software
Use Panel View to Check PLC Software
Step# 3 Logic to Open/Close Valve V2 – Drain Valve
Mixer and Blender Download PLC Software
Use Panel View to Check PLC Software
Formula to calculate Volume the Cylinder Tank in gallons
Implement PLC Software to calculate Volume the Tank
PLC Software to calculate Volume the Tank
■ Agenda NEW THINKING. NEW POSSIBILITIES

Hands on Lab 1: Mixer And Blender and Tank

Mixer and Blender Download PLC Software
Use Panel View to Check PLC Software
Hands on Lab 2: Elevator
Introduction the Lab – Elevator 2 Positions
PLC Tags to simulate Panel Builder Animation
PLC Software Create Routine Elevator
Use JSR instruction – call PLC routine Elevator
Step#1 Move Elevator from Position 0 to Position 1
Step#1 Implemented the PLC Logic to Move Elevator Up
Step#2 Implemented the PLC Logic to Move Elevator Down
Elevator Download PLC Software
Hands on Lab 3: Electronic Locker
Introduction the Lab – Electronic Locker
PLC Tags to simulate Panel Builder Animation
30 Minutes to Implement the PLC Logic
Hands on Lab 4: Traffic Control Lights
Introduction the Lab – Traffic Control Lights
PLC Tags to simulate Panel Builder Animation
30 Minutes to Implement the PLC Logic
■ Hands on Lab#1 PLC3 NEW THINKING. NEW POSSIBILITIES
■ Hands on Lab#2 PLC3 NEW THINKING. NEW POSSIBILITIES
■ Hands on Lab#3 PLC3 NEW THINKING. NEW POSSIBILITIES
■ Hands on Lab#3 PLC3 NEW THINKING. NEW POSSIBILITIES
■ Hands on Lab#4 PLC3 NEW THINKING. NEW POSSIBILITIES
■ Introduction the Lab – Mixer and Blender NEW THINKING. NEW POSSIBILITIES

This Lab#1 will implement PLC Software

To control the level the Tank and Start
The Agitator
See the Steps Below:

1. Panel Builder Push Start Button

2. Level <= 10% Open V1
3. Level >= 90% Close V1
4. Start A1 for 30 sec
5. Level >= 90% Open V2
6. Level <= 10% Close V2
7. Return to Step#2

Push Stop Button Set Hmax = 6.0 and Radius = 2.0 and Check
calculations made by PLC Height, Volume
■ PLC Tags to simulate Panel Builder Animation NEW THINKING. NEW POSSIBILITIES

T1.  timer
A1  Bool V1  Bool

Start  Bool

Level  Dint Hmax Real R Real

Stop  Bool

H Real V Real

V2  Bool

All Tags were created in Controller TAG

■ PLC Software Open Project  PLC3.ACD NEW THINKING. NEW POSSIBILITIES

1 Select Windows XP  Start  All Programs  Rockwell Software  RSLogix 5000

2 Open  RSLogix 5000

4 Select  Folder  PLC3 Training

3 Select  Open
5

Select  File  PLC3.ACD

■ PLC Software Create Routine Mixer and Blender NEW THINKING. NEW POSSIBILITIES

Right Click Mouse : MainProgram 1

Select : New Routine 2

3
5

5
■ Use JSR instruction – call PLC routine Mixer and Blender NEW THINKING. NEW POSSIBILITIES

Double Click : MainProgram 1

Use JSR to call Mixer_and_Blender routine 2

■ How Implement PLC Instructions RSLogix 5000 NEW THINKING. NEW POSSIBILITIES

■ Tip: use Group or Shortcut to input instructions in your PLC Software

Ex: Compare  CMP,LIM,MEQ,EQU,NEQ,LES,GRT,GEQ

Ex: Bit  -| |- , -|/|- , -( )- , -( L )- , -(U)- , -[ONS]-

Type instructions
Or use Shortcut  Keyboard  Insert Key 

Click Ok
■ Step#1 Logic to Open/Close Valve V1 – Make Up Valve NEW THINKING. NEW POSSIBILITIES

1
■ V1 Open Level <= 10%
Double Click : Mixer_and_Blender
■ V1 Close Level >= 80%

Create Tags Shoot1 and Shoot2  Controller Tag

Type the Logic Above 2

■ Mixer and Blender Download PLC Software NEW THINKING. NEW POSSIBILITIES

Station#1  192.168.0.111

Station#2  192.168.0.112

Station#3  192.168.0.113

Station#4  192.168.0.114

Station#5  192.168.0.115
■ Use Panel View to Check PLC Software NEW THINKING. NEW POSSIBILITIES

1. Panel Builder Push Start Button

2. Tank will be filled until Reach 80%
3. V1 Open Level <= 10%
4. V1 Close Level >= 80%
■ Step#2 Implemented PLC Logic to temporize Agitator NEW THINKING. NEW POSSIBILITIES

■ Instructions
■ Tag A1 (Bool-Controller) was already create
■ Use A1 To Start the Agitator
■ Set Timer 30 sec to Keep the Agitator Running

5 Minutes to Implement the PLC Logic

1 Step2 is made
2 Start Timer T1
3 T1.TT made
?
4 Set A1

Internal Tags Input Tags Output Tags

Step1  Bool Level  Dint V1  Bool
Step2  Bool V2  Bool
T1  Timer A1  Bool
■ Step#2 Implemented PLC Logic to temporize Agitator NEW THINKING. NEW POSSIBILITIES

■ Example the PLC Logic

Type the Logic Above 1

■ Mixer and Blender Download PLC Software NEW THINKING. NEW POSSIBILITIES

Station#1  192.168.0.111

Station#2  192.168.0.112

Station#3  192.168.0.113

Station#4  192.168.0.114

Station#5  192.168.0.115
■ Use Panel View to Check PLC Software NEW THINKING. NEW POSSIBILITIES

1. Check A1 is on for 30 sec

■ Step# 3 Logic to Open/Close Valve V2 – Drain Valve NEW THINKING. NEW POSSIBILITIES

■ Instructions
■ V2 Open Level >= 80%
■ V2 Close Level <= 10%

5 Minutes to Implement the PLC Logic

1 Step2 is made
2 Level >= 80% ?
3 Latch V2
4 Level <= 10%
5 Unlatch V2,Step1,Step2

Internal Tags Input Tags Output Tags

Step1  Bool Position  Dint V1  Bool
Step2  Bool V2  Bool
T1  Timer A1  Bool
Level  Dint
■ Step# 3 Logic to Open/Close Valve V2 – Drain Valve NEW THINKING. NEW POSSIBILITIES

■ Example the PLC Logic

Type the Logic Above 1

Create Tags Shoot3  Controller Tag

■ Mixer and Blender Download PLC Software NEW THINKING. NEW POSSIBILITIES

Station#1  192.168.0.111

Station#2  192.168.0.112

Station#3  192.168.0.113

Station#4  192.168.0.114

Station#5  192.168.0.115
■ Use Panel View to Check PLC Software NEW THINKING. NEW POSSIBILITIES

1. V2 Open Level >=80

2. V2 Close Level <= 10%
■ Formula to calculate Volume the Cylinder Tank in gallons NEW THINKING. NEW POSSIBILITIES

R
6 ft
V = 3.14 * R² * H

1 ft³ = 7.48051948 gal

Volume (gal) = 3.14 * R² * H *7.48

H H = 6.0 ft / R = 3.0 ft

Level  100%  6.0 ft

Level  0%  0.0 ft

0 ft
■ Implement PLC Software to calculate Volume the Tank NEW THINKING. NEW POSSIBILITIES

■ Instructions
■ Volume tag V  Real already created
■ Height tag H  Real Already created

■ Tip : first convert Height % to ft  H = ( Level(%) * Hmax)/100

■ V = 3.14 * R² * H * 7.48 ■ Hmax = 6.0 ft / R = 2.0 ft

5 Minutes to Implement the PLC Logic

?
■ PLC Software to calculate Volume the Tank NEW THINKING. NEW POSSIBILITIES

■ Tip : Set Hmax = 6.0 / R= 2.0

Type the Logic Above 1

■ Mixer and Blender Download PLC Software NEW THINKING. NEW POSSIBILITIES

Station#1  192.168.0.111

Station#2  192.168.0.112

Station#3  192.168.0.113

Station#4  192.168.0.114

Station#5  192.168.0.115
■ Use Panel View to Check PLC Software NEW THINKING. NEW POSSIBILITIES

Use Stop Button to see the calculations Made by PLC

■ Introduction the Lab – Elevator 2 Positions NEW THINKING. NEW POSSIBILITIES

This Lab#2 will implement PLC Software

To control the Position off the Elevator

See the Steps Below:

Elevator Move Up
1 Elevator in Position 0
2 Panel Builder Push P1
3 Elevator Move Up Fast
4 High_Slow switch is made
5 Elevator Move Up Slow
6 High switch is Made
7 Elevator Stop in Position 1

Elevator Move Down

1 Elevator in Position 1
2 Panel Builder Push P0
3 Elevator Move Down Fast
4 Low_Slow switch is made
5 Elevator Move Down Slow
6 Low switch is Made
7 Elevator Stop in Position 0
■ PLC Tags to simulate Panel Builder Animation NEW THINKING. NEW POSSIBILITIES

High Bool

P1 Bool

High_Slow Bool

Position  Dint Up Bool

Fast Bool

Slow Bool
Down Bool

Low_Slow Bool

P0  Bool

Low Bool

All Tags were created in Controller TAG

■ PLC Software Create Routine Elevator NEW THINKING. NEW POSSIBILITIES

Right Click Mouse : MainProgram 1

Select : New Routine 2

3
5

5
■ Use JSR instruction – call PLC routine Elevator NEW THINKING. NEW POSSIBILITIES

Double Click : MainProgram 1

Use JSR to call Elevator routine 2

■ Step#1 Move Elevator from Position 0 to Position 1 NEW THINKING. NEW POSSIBILITIES

Double Click : Mixer_and_Blender 1

10 Minutes to Implement the PLC Logic 2

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Elevator Move Up Input Tags Output Tags
High Bool Up Bool
1 Elevator in Position 0  Low Switch Made
High_Slow  Bool Down  Bool
2 Panel Builder Push P1  Push P1
Low_Slow  Bool Fast  Bool
3 Elevator Move Up Fast  Latch Tags Up, Fast
Low  Bool Slow  Bool
4 High_Slow switch is made  High_Slow Switch Made
5 Elevator Move Up Slow  Latch Tags Up, Slow, Unlatch Fast
6 High Switch is Made  High_Switch made
7 Elevator Stop in Position 1  Unlatch Tags Up, Slow
■ Step#1 Implemented the PLC Logic to Move Elevator Up NEW THINKING. NEW POSSIBILITIES

■ Example the PLC Logic

Type the Logic Above 1

Create Tags Shoot4 and Shoot5  Controller Tag

■ Step#2 Implemented the PLC Logic to Move Elevator Down NEW THINKING. NEW POSSIBILITIES

■ Example the PLC Logic

Type the Logic Above 1

Create Tags Shoot6 and Shoot7  Controller Tag

■ Elevator Download PLC Software NEW THINKING. NEW POSSIBILITIES

Station#1  192.168.0.111

Station#2  192.168.0.112

Station#3  192.168.0.113

Station#4  192.168.0.114

Station#5  192.168.0.115
■ Use Panel View to Check PLC Software NEW THINKING. NEW POSSIBILITIES

Push P1/P0 to move the elevator Up/Down

■ Introduction the Lab – Electronic Locker NEW THINKING. NEW POSSIBILITIES

This Lab#2 will implement PLC Software

For release the Electronic Locker

See the Steps Below:

1 Push Reset
1 L1 Green
2 Push #Key
3 Display#1 Loaded
4 L2 Green
5 Push #Key
6 Display#2 Loaded
7 L3 Green
8 Push #Key
9 Display#3 Loaded
10 Push Enter
■ PLC Tags to simulate Panel Builder Animation NEW THINKING. NEW POSSIBILITIES

K0 K1 K2 K3 K4  Bool

K5 K6 K7 K8 K9  Bool

Display1 Dint Display2 Dint Display3 Dint

L1  Bool L2  Bool L3  Bool

Code_Ok  Bool

Reset  Bool Enter  Bool

Code_NOk  Bool

All Tags were created in Controller TAG

■ PLC Tags to simulate Panel Builder Animation NEW THINKING. NEW POSSIBILITIES

Password1 Dint Password2 Dint Password3 Dint

All Tags were created in Controller TAG

■ Electronic Locker NEW THINKING. NEW POSSIBILITIES

30 Minutes to Implement the PLC Logic

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 ■ Introduction the Lab – Traffic Control Lights NEW THINKING. NEW POSSIBILITIES

This Lab#4 will implement PLC Software for Traffic Control Lights

See the Steps Below: Off mode all Lights should be Off
1 Push Start Button
1 Lane B,C Red light On
1 Lane A,B,C Yellow Light Off
1 Lane B,C Green Light Off
2 Lane A Green Light On 30s
3 Lane A Green Light Off
3 Lane A Yellow Light On 5s
4 Lane A Yellow Light Off
4 Lane A Red Light On
4 Lane B Red Light Off
4 Lane B Green Light On 30s
5 Lane B Green Light Off
5 Lane B Yellow Light On5s
6 Lane B Yellow Light Off
6 Lane B Red Light On
6 Lane C Red Light Off
6 Lane C Green Light On 30s
7 Lane C Green Light Off
7 Lane C Yellow Light On5s
8 Lane C Yellow Light Off
8 Lane C Red Light On
9 Go to Step 2 Start Button set System ON / Stop Button Set System Off
■ PLC Tags to simulate Panel Builder Animation NEW THINKING. NEW POSSIBILITIES

A_Red B_Red
A_Yellow B_Yellow
A_Green B_Green

TA Timer Bool Bool TB Timer

Bool
On  Bool
C_Red
C_Yellow
Off  Bool C_Green

TC Timer

All Tags were created in Controller TAG

■ Traffic Control Lights NEW THINKING. NEW POSSIBILITIES

30 Minutes to Implement the PLC Logic